DE102010046467A1 - Device, useful for manufacturing, repairing and/or replacing component, preferably aircraft component by powder solidifiable by radiation energy of radiation energy source, comprises fixed construction platform with frame - Google Patents

Abstract

Device (10) comprises a fixed construction platform (20) with a frame surrounding the construction platform for receiving a powder (16) on the construction platform, where the frame is designed to be movable. Independent claims are also included for: (1) manufacturing, repairing and/or replacing a component (12), preferably an aircraft component, comprising providing a radiation energy source (14) for solidifying the powder, which is solidifiable by radiation energy, providing a fixed construction platform with a movable frame surrounding the platform, moving the frame such that a powder layer of the powder is affixed on the construction platform, and solidifying a component region of the powder layer by the radiation energy source; and (2) a component which is manufactured, repaired and/or replaced.

Description

The present invention relates to a device for producing, repairing and / or replacing a component by means of at least one powder which can be solidified by an energy radiation. The component is here, for example, an aircraft component such. B. a blade element of an aircraft engine, such as a turbine engine. In principle, however, the device and the method can also be used for any other component which can be produced or processed by means of a powder which can be solidified by energy radiation. The powder is thereby sintered or melted by the energy radiation to be solidified.

From the state of the art, as in the WO 2008/125497 A1 is disclosed, a device is known for the direct construction of components made of high-temperature metals. The device in this case has an electron beam generating device, which is designed such that it directs an electron beam controlled by a control of a computer to any predefined positions of a powder bed. The electron beam device is movable in a horizontal direction or in an X and Y direction. Scanning of the electron beam over the entire area of a part platform on which a component is to be produced can be carried out by known electron beam devices with a fixed beam generating device. The powder bed is movable up and down in a vertical direction or Z direction by the part platform by means of a motor. In this case, the parts platform is formed by a frame in which the parts platform is guided so that in the frame above the parts platform a loose powder is added. Furthermore, a coating device is provided which can be manipulated via the powder bed in order to apply a new layer of powder. The powder with the coating device is located in a space that can be evacuated or filled with a gas atmosphere.

In this device, the part platform must be moved. This has the disadvantage that components that are built on the part platform, often have rough surfaces, since the part platform in the layered process, not always can be accurately positioned. This has the consequence that component layers can be slightly offset from one another, which leads to a rough surface.

A very big disadvantage is that the installation space limits the installation space.

Furthermore, from the DE 100 53 742 C5 discloses an apparatus for sintering, abrading and / or inscribing a workpiece. In this case, a construction space is provided in a machine housing, in which a scanner is arranged, in which the beam of a sintered laser is coupled. Furthermore, a height-adjustable workpiece platform is provided, as well as a material supply device for feeding sintered material from a storage container. The scanner is arranged in the manner of a cross slide on a motor-driven scanner carrier for moving the scanner in a horizontal direction or X and Y direction over the workpiece platform. The scanner can also be provided along a Z-axis, ie adjustable in height, movable. The sintering laser itself is in turn fixedly arranged on a machine frame connected to a cross slide assembly of the suspension. The irradiation of the beam of the sintered laser into the area of the scanner carrier takes place parallel to axes of the suspension of the scanner carrier and via 90 ° deflection mirror to the optical input of the scanner.

In the apparatus described above, the beam source, i. H. here the sintering laser, even firm. Instead, the scanner is designed movable and positioned on a kind of cross slide.

The object of the invention is to provide an improved device and an improved method for producing or repairing and / or replacing a component by means of a powder to be solidified by energy radiation.

According to the invention, there is now provided an apparatus and method for forming, repairing and / or replacing a component.

More specifically, an apparatus is provided for fabricating, repairing and / or replacing a component by means of a powder solidifiable by energy radiation of an energy source, the apparatus comprising a fixed build platform having a frame surrounding the build platform for receiving a powder on the build platform, the frame is formed movable.

The device has the advantage that components with a better surface can be produced by the fixed construction platform and the frame movable to the construction platform for applying the powder. The fact that the construction platform is not moved but only the frame, the risk of the occurrence of an offset in the solidified powder layers can be avoided. As a result, the surface of the component can be improved.

The space can be easily increased in this way, allowing larger components can be produced.

Furthermore, a method is provided for producing, repairing and / or replacing a component, the method having the following steps:
Providing an energy radiation source for solidifying a powder solidifiable by the energy radiation source;
Providing a fixed building platform with a movable frame surrounding the build platform for receiving the powder on the build platform;
Moving the frame such that a powder layer of the powder is applied to the build platform: and
Solidifying a component region of the powder layer by the energy radiation source.

By moving the frame rather than the build platform to apply the powder layer by layer and then solidify the component area of the powder, an offset of the individual powder layers can be avoided and components with a smoother surface can be produced.

Advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the description with reference to the drawings.

In one embodiment of the invention, the energy radiation of the energy radiation source is adjustable at least in a vertical (Z-direction). In this way, the distance between the focus of the energy beam, z. As a laser beam, are adjusted so that it meets the respective powder layer, so that the respective powder layer can be suitably solidified in a component region.

In another embodiment according to the invention, the energy radiation of the energy radiation source is additionally movable in at least one or two additional spatial directions or in the X and / or Y direction. As a result, the energy beam can be moved virtually parallel or in a horizontal direction or horizontal plane to the respective powder bed and solidify it in the component area.

The invention will be explained in more detail with reference to the exemplary embodiments indicated in the schematic figures of the drawings. Show it:

1 a schematic view of a device according to an embodiment of the invention; and

2 a diagram illustrating the method for producing a component according to the invention.

The invention is directed in particular to the field of application of additive manufacturing for the production of components. This includes so-called rapid manufacturing or so-called rapid prototyping. In generative manufacturing, components are built up, in particular, in layers by material application. Hereby, in the corresponding processes known as Electron Beam Melting (EBM), LaserCusing, Selective Laser Sintering (SLS), Selective Laser Melting (SLM) or 3D Printing, the material to be added or applied is processed in powder form. The powder is hereby applied in particular layer by layer on a building platform or a carrier. Subsequently, the powder layer is selectively solidified by means of energy radiation, such as. B. a laser beam or electron beam.

The solidification of the respective powder layer is normally carried out on the basis of geometric data of the component to be produced. In this case, the area of the powder layer z. B. scanned and belonging to the corresponding component layer section are solidified by energy radiation. The powder melts or sinters in this area as a result of the action of energy radiation. In the case of 3D printing, the powder layer is solidified by selectively introducing a binder into the component-associated areas. Subsequently, the construction platform or the carrier can be moved by a layer thickness, for. B. be lowered. Then a new layer of powder is applied over it and solidified again. In this way, layer by layer, the component, such as a blade element or a part of a blade element, built or supplemented, for. B. in the case of a repair.

In 1 Figure 3 is a schematic view of an embodiment of a device 10 for making, repairing and / or replacing a component 12 by at least one by an energy source 14 to be solidified powder 16 , The powder 16 is thereby by the energy radiation 18 the energy source 14 z. B. melted or sintered and solidified. The powder 16 can be composed of one or more materials, for example, the powder 16 at least one metal powder, a metal alloy powder, a ceramic powder and / or a plastic powder, to name but a few examples of the powder 16 to call. The invention is not limited to these examples. In principle, every powder 16 be used from a material or a combination of materials, which is suitable by means of an energy radiation source, such as. As an electron beam or a laser beam to be solidified. However, the invention is directed to laser beams and electron beams as energy radiation 18 not limited. Basically, any other source of energy radiation 14 can be used, which is suitable to solidify an associated powder.

As in 1 the schematic representation of an embodiment of the device according to the invention 10 is shown, the device 10 a build platform 20 or a support on which at least one component 12 is trained. The construction platform 20 or the carrier is fixed and z. B. by a frame 22 limited, leaving a powder 16 can be included in it. Unlike the build platform 20 which is not moved or is stationary, is the frame 22 movably designed. That means the frame 22 moved up and down or in Z-direction in 1 is trained. The frame 22 So it's going to be along the fixed build platform 20 moved up and down, leaving the build platform 20 via a coating device 24 with a powder 16 can be coated. As a coating device 24 can, for example, a scraper device, as in 1 is shown, a squeegee and / or at least one Pulverzuführdüse etc. are provided.

In 1 now at least one component 12 composed of several layers of powder. For applying the respective powder layer 16 by means of the coating device 24 now becomes the frame 22 each moved upward so that a corresponding powder layer on the build platform 20 can be applied. Subsequently, the powder layer is solidified in the component areas by means of the energy radiation source. Then the frame drives 22 in each case again a piece up in 1 so that the next layer of powder on the build platform 20 or the previously partially solidified now powder layer and then in the component areas also by means of the energy radiation source 14 can be solidified. By the construction platform 20 fixed, ie not moved, but instead the building platform 20 enclosing frames 22 , can be a component 12 be manufactured with a higher accuracy and surface finish. This is because the build platform 20 is fixed and so no offset can occur as when moving the build platform to provide the powder layers in the prior art. The movement of the frame is much less critical.

For solidifying the respective powder layer in selected areas, here the component areas, the energy beam 18 the energy source 14 , z. B. a laser in 1 , adjusted accordingly. This means that the distance of the laser or its focus from the powder bed, which is to be solidified in areas through him, is set so that z. B. the focus of the laser beam as optimally or accurately hits the surface of the area to be solidified. These are z. B. the energy source 14 and / or at least part of an optical beam guidance system (not shown) for guiding an energy beam of the energy radiation source 14 designed to be movable, in particular in the Z direction. Furthermore, z. B. the energy source 14 and / or at least a part of the optical beam guidance system in addition to the mobility in the Z direction also be designed to be movable in the X direction and / or Y direction.

This can z. B. the energy source 14 similar to the scanner in the previously described with reference to the prior art DE 100 53 742 C5 on a cross slide as adjusting device 26 be arranged, which in the X-direction, Y-direction and Z-direction movable or movable. This also applies to the beam guidance system or parts of the beam guidance system. Likewise, z. B. the energy source 14 and / or at least a part of the beam guidance system also on a robot or a robot arm, as in 1 indicated as adjusting 26 be arranged, which is movable in the Z direction and optionally additionally in the X direction and / or Y direction, as in 1 shown. However, the invention is based on the two examples mentioned as adjusting devices 26 for the movable arrangement of the energy radiation source 14 and / or at least part of an optical beam guidance system for the energy beam is not limited.

Because the build platform 20 itself is fixed, a scanner does not necessarily have to be provided for scanning the powder layer. Instead, the position of the build platform 20 and the data or three-dimensional data of each component to be manufactured 12 on the component platform 20 be predetermined or stored in advance, so that the powder layer on the fixed build platform 20 does not have to be scanned additionally. Instead, enough suitable data is provided, e.g. B. via a to the adjustment 26 connected computer 30 which the adjusting device 26 and the operation of the energy radiation source 14 for solidifying the powder of the corresponding powder layer and / or the beam guiding system in predetermined component areas controls.

Basically, but also an additional scanner 28 be provided as in 1 is indicated by a dashed line, which z. B. with the energy source 14 and / or an optical beam guidance system can be coupled and can also be provided on the adjusting movable or movable.

As in 1 Shown is the build platform 20 with the movable frame 22 , the energy source of radiation 14 and optionally the scanner 28 in a process chamber 32 be arranged. The process chamber 32 in 1 can optionally additionally evacuated and / or gas z. B. a noble gas atmosphere be formed, depending on the function and purpose. Likewise, the process chamber 32 depending on the function and purpose also omitted.

Next to a ray 18 which z. B. is guided over an optical beam guidance system, for example, mirrors and / or lenses, for example, at least one optical waveguide, z. B. at least one glass fiber, are provided, which conducts a light beam and wherein the at least one optical waveguide with the adjusting device to be connected or coupled in accordance with, for solidifying the powder.

In 2 a diagram is shown for illustrating the method for producing, repairing and / or replacing a component according to the invention.

According to the invention, a fixed component platform is provided with a surrounding movable frame. In this case, the frame is moved to a position (step S1) in which a powder layer is applied to the component platform via a coating device. The energy beam of the energy radiation source is adjusted so that it solidifies the applied powder layer in predetermined component areas. For this purpose, for example, the energy radiation source is positioned correspondingly in the Z direction via an adjusting device (step S2). The powder is then solidified in the component regions via the energy radiation source (step S3). As described above, for positioning the energy beam relative to the respective powder layer applied, the energy radiation source, a part of the energy radiation source, at least a part of an optical beam guidance system for an energy beam and / or at least one optical fiber for guiding an energy beam relative to the powder bed ., formed or arranged movable in the Z direction. In this way, the energy beam can be suitably adjusted to solidify the powder bed. For example, a laser beam with its focus can be adjusted so that it always hits with its focus on the powder bed and thus solidifies the powder suitable.

The movable source of radiation (i.e., energy source, beam delivery system, or fiber) has the advantage of increasing flexibility and also allowing increased space. In this way the investment flexibility can be increased. Large installation spaces can be provided for many and / or large component with one or more component platforms and frame. Furthermore, small spaces can be used for the economic production of small parts. Two variants of a mobile radiation source are of particular importance. A mobility only in Z-direction allows the increase in height. A mobility in all spatial directions, d. H. X-, Y- and Z-direction allows an increase of the installation space in all dimensions. In addition, with such a system concept, an energy radiation source can be used for several installation spaces. In this way, the disadvantage of long cooling processes, which can sometimes be longer than the production itself, z. B. neutralized in the electron beam technology or at least reduced.

Although the present invention has been described above with reference to the preferred embodiments, it is not limited thereto, but modified in many ways. In particular, the embodiments described above can be combined with one another, in particular individual features thereof.

LIST OF REFERENCE NUMBERS

10

contraption

12

component

14

Energy radiation source

16

powder

18

energy radiation

20

building platform

22

frame

24

coater

26

adjustment

28

scanner

30

computer

32

process chamber

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2008/125497 A1 [0002]
• DE 10053742 C5 [0005, 0026]

Claims (11)

Contraption ( 10 ) for producing, repairing and / or replacing a component ( 12 ), in particular an aircraft component, by means of an energy radiation of an energy radiation source ( 14 ) solidifiable powder ( 16 ), characterized in that the device ( 10 ) a fixed building platform ( 20 ) with a build platform ( 20 ) surrounding frame ( 22 ) for receiving a powder ( 16 ) on the build platform ( 20 ), the frame ( 22 ) is designed movable. Device according to claim 1, characterized in that the energy radiation ( 18 ) of the energy source ( 14 ) is adjustable at least in a vertical (Z-direction). Device according to claim 2, characterized in that the energy radiation ( 18 ) of the energy source ( 14 ) is movable in at least one or two additional spatial directions (X-direction, Y-direction). Device according to one of the preceding claims, characterized in that for movement of the energy beam ( 18 ) of the energy source ( 14 ) at least a part of a beam guiding system of the energy beam ( 18 ) of the energy source ( 14 ) and / or at least one optical fiber for guiding the energy beam ( 18 ) of the energy source ( 14 ) with an adjusting device ( 26 ) is connected or coupled. Device according to one of the preceding claims, characterized in that the device comprises a scanner ( 28 ), wherein the scanner ( 28 ) with the adjusting device ( 26 ) can be coupled. Device according to one of claims 4 or 5, characterized in that the adjusting device ( 26 ) as a carriage, in particular as a in all three spatial directions (X-direction, Y-direction, Z-direction) movably trained cross slide, or as a robot arm ( 26 ) is formed, which in particular in all three spatial directions (X-direction, Y-direction, Z-direction) is designed to be movable. Device according to one of the preceding claims, characterized in that the energy radiation source ( 14 ) is designed as a laser or an electron beam source. Method for producing, repairing and / or replacing a component ( 12 ), in particular an aircraft component, the method comprising the steps of: providing an energy radiation source ( 14 ) for solidifying a by means of the energy radiation source ( 14 ) solidifiable powder ( 16 ); Providing a fixed build platform ( 20 ) with a build platform ( 20 ) surrounding movable frame ( 22 ) for receiving the powder ( 16 ) on the build platform ( 20 ); Moving the frame ( 22 ) such that a powder layer of the powder ( 16 ) on the build platform ( 20 ) can be applied; and solidifying a component region of the powder layer by the energy radiation source ( 14 ). A method according to claim 8, characterized in that the method further comprises the step of: adjusting the distance of the focus of the energy radiation ( 18 ) of the respective powder layer or powder ( 16 ) for solidifying a component region of the powder layer. Component which is manufactured, repaired and / or replaced according to the method of claim 8 or 9. Component according to claim 10, characterized in that the component ( 12 ) is a blade element, in particular an aircraft engine.

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